11 Service Work On The Chassis

Transcript

OWNER'S MANUAL 2013 690 SMC R EU 690 SMC R AUS/UK Art. no. 3211954en DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. DEAR KTM CUSTOMER We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Chassis number ( p. 20) Engine number ( p. 21) Key number ( Dealer's stamp p. 21) The Owner's Manual contained the latest information for this model at the time of going to print. Minor differences due to developments in design cannot be ruled out completely. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply. © 2012 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. DEAR KTM CUSTOMER ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria 2 TABLE OF CONTENTS TABLE OF CONTENTS 1 2 3 4 5 MEANS OF REPRESENTATION ........................................ 7 1.1 Symbols used ...................................................... 7 1.2 Formats used....................................................... 7 SAFETY ADVICE.............................................................. 8 2.1 Use definition - intended use ................................ 8 2.2 Safety advice....................................................... 8 2.3 Degrees of risk and symbols .................................. 9 2.4 Tampering warning............................................... 9 2.5 Safe operation ................................................... 10 2.6 Protective clothing ............................................. 11 2.7 Work rules......................................................... 11 2.8 Environment...................................................... 11 2.9 Owner's Manual ................................................. 12 IMPORTANT NOTES...................................................... 13 3.1 Guarantee, warranty ........................................... 13 3.2 Operating and auxiliary substances ...................... 13 3.3 Spare parts, accessories ..................................... 13 3.4 Service ............................................................. 13 3.5 Figures ............................................................. 14 3.6 Customer service................................................ 14 VIEW OF VEHICLE ........................................................ 16 4.1 View of vehicle, front left side (example) .............. 16 4.2 View of vehicle, rear right side (example).............. 18 SERIAL NUMBERS ....................................................... 20 5.1 Chassis number ................................................. 20 5.2 Type label ......................................................... 20 5.3 Key number....................................................... 21 5.4 Engine number .................................................. 21 5.5 Fork part number ............................................... 22 3 6 5.6 Shock absorber part number ............................... CONTROLS................................................................... 6.1 Clutch lever....................................................... 6.2 Hand brake lever................................................ 6.3 Throttle grip ...................................................... 6.4 Horn button....................................................... 6.5 Light switch ...................................................... 6.6 Turn signal switch.............................................. 6.7 Emergency OFF switch ....................................... 6.8 Electric starter button......................................... 6.9 Ignition/steering lock .......................................... 6.10 Combination instrument ..................................... 6.10.1 Overview ....................................................... 6.10.2 Function buttons ........................................... 6.10.3 Tachometer ................................................... 6.10.4 Indicator lamps ............................................. 6.10.5 Display ......................................................... 6.10.6 Speed display................................................ 6.10.7 Setting kilometers or miles ............................. 6.10.8 Time............................................................. 6.10.9 Setting the clock ........................................... 6.10.10 ODO display .................................................. 6.10.11 Setting/resetting display TRIP 1 ...................... 6.10.12 Setting/resetting display TRIP 2 ...................... 6.10.13 TRIP F display............................................... 6.10.14 Coolant temperature indicator ......................... 6.11 Opening the filler cap......................................... 6.12 Closing filler cap................................................ 6.13 Seat release ...................................................... 22 23 23 23 24 24 25 25 26 26 27 27 27 28 28 29 30 31 31 32 32 33 33 34 35 35 36 37 37 TABLE OF CONTENTS 6.14 Handrails .......................................................... 6.15 Passenger footrests ............................................ 6.16 Shift lever ......................................................... 6.17 Foot brake lever ................................................. 6.18 Side stand......................................................... 7 PREPARING FOR USE................................................... 7.1 Advice on first use ............................................. 7.2 Running in the engine ........................................ 7.3 Loading the vehicle ............................................ 8 RIDING INSTRUCTIONS................................................ 8.1 Performing checks and vehicle care when preparing for use................................................ 8.2 Starting............................................................. 8.3 Starting off........................................................ 8.4 Shifting, riding .................................................. 8.5 Braking ............................................................. 8.6 Stopping, parking............................................... 8.7 Transport .......................................................... 8.8 Refueling .......................................................... 9 SERVICE SCHEDULE .................................................... 9.1 Service schedule................................................ 10 TUNING THE CHASSIS ................................................. 10.1 Fork/shock absorber ........................................... 10.2 Adjusting the compression damping of the fork..... 10.3 Adjusting the rebound damping of the fork ........... 10.4 Compression damping of the shock absorber......... 10.5 Adjusting the low-speed compression damping of the shock absorber ............................................. 10.6 Adjusting the high-speed compression damping of the shock absorber ......................................... 4 38 38 39 40 40 41 41 42 43 45 45 46 47 47 51 52 53 54 57 57 60 60 60 61 62 62 63 10.7 Adjusting the rebound damping of the shock absorber............................................................ 10.8 Handlebar position............................................. 10.9 Adjusting the handlebar position .................... 11 SERVICE WORK ON THE CHASSIS................................. 11.1 Raising the motorcycle with a lift stand................ 11.2 Removing the motorcycle from the lift stand......... 11.3 Raising the motorcycle with the rear wheel stand ................................................................ 11.4 Taking the motorcycle off of the rear wheel stand ................................................................ 11.5 Raising the motorcycle with the front wheel stand ................................................................ 11.6 Taking the motorcycle off of the front wheel stand ................................................................ 11.7 Bleeding the fork legs......................................... 11.8 Cleaning the dust boots of the fork legs................ 11.9 Removing the fork protector ................................ 11.10 Installing the fork protector................................. 11.11 Removing the seat ............................................. 11.12 Mounting the seat .............................................. 11.13 Removing the air filter ................................... 11.14 Installing the air filter .................................... 11.15 Checking the chain for dirt.................................. 11.16 Cleaning the chain ............................................. 11.17 Checking the chain tension ................................. 11.18 Adjusting the chain tension................................. 11.19 Check the chain, rear sprocket, engine sprocket, and chain guide ................................................. 11.20 Adjusting basic position of clutch lever ................ x x x 64 65 66 67 67 67 68 69 69 70 70 71 72 73 73 74 74 75 76 77 78 79 80 84 TABLE OF CONTENTS 5 11.21 Checking/rectifying the fluid level of the hydraulic clutch................................................. 85 12 BRAKE SYSTEM ........................................................... 86 12.1 Adjusting the basic position of the hand brake lever ................................................................. 86 12.2 Checking the brake discs .................................... 86 12.3 Checking the front brake fluid level ..................... 87 12.4 Adding front brake fluid ................................. 88 12.5 Checking the front brake linings .......................... 89 12.6 Checking the free travel of foot brake lever ........... 90 12.7 Adjusting the basic position of the foot brake lever ............................................................ 91 12.8 Checking rear brake fluid level ............................ 92 12.9 Adding rear brake fluid .................................. 92 12.10 Checking the rear brake linings ........................... 94 13 WHEELS, TIRES ........................................................... 96 13.1 Removing front wheel .................................... 96 13.2 Installing the front wheel ............................... 97 13.3 Removing rear wheel ..................................... 99 13.4 Installing the rear wheel .............................. 100 13.5 Checking the rear hub rubber dampers .......... 102 13.6 Checking the tire condition ............................... 104 13.7 Tubeless tire system......................................... 106 13.8 Checking the tire air pressure............................ 106 13.9 Checking the spoke tension............................... 107 14 ELECTRICAL SYSTEM ................................................. 109 14.1 Removing the battery .................................. 109 14.2 Installing the battery ................................... 110 14.3 Recharging the battery ................................ 111 x x x x x x x x x x x 14.4 14.5 14.6 Changing the main fuse .................................... Changing fuses of individual power consumers.... Removing the headlight mask with the headlight......................................................... 14.7 Installing the headlight mask with the headlight......................................................... 14.8 Changing the headlight bulb ............................. 14.9 Changing the parking light bulb......................... 14.10 Changing the turn signal bulb ........................... 14.11 Checking the headlight setting .......................... 14.12 Adjusting the headlight range............................ 15 COOLING SYSTEM ...................................................... 15.1 Cooling system ................................................ 15.2 Checking the antifreeze and coolant level ........... 15.3 Checking the coolant level ................................ 15.4 Draining the coolant .................................... 15.5 Filling/bleeding the cooling system ............... 16 TUNING THE ENGINE................................................. 16.1 Checking the play in the throttle cable ............... 16.2 Adjusting the play in the throttle cable .......... 16.3 Adjusting the engine characteristic .................... 16.4 Checking the basic position of the shift lever ...... 16.5 Adjusting the basic position of the shift lever .......................................................... 17 SERVICE WORK ON THE ENGINE ................................ 17.1 Checking the engine oil level............................. 17.2 Changing the engine oil and filter, cleaning the oil screens .................................................. 17.3 Draining the engine oil ................................ x x x x x x 114 115 117 119 120 122 123 124 125 126 126 126 128 130 131 133 133 133 134 136 136 138 138 139 139 TABLE OF CONTENTS 17.4 Removing the oil filter ................................. 17.5 Cleaning the oil screens ............................... 17.6 Installing the oil filter .................................. 17.7 Filling up with engine oil ............................. 17.8 Adding engine oil ............................................. CLEANING, CARE ....................................................... 18.1 Cleaning the motorcycle ................................... 18.2 Checks and maintenance steps for winter operation......................................................... STORAGE ................................................................... 19.1 Storage ........................................................... 19.2 Preparing for use after storage........................... TROUBLESHOOTING .................................................. BLINK CODE .............................................................. TECHNICAL DATA....................................................... 22.1 engine ............................................................ 22.2 engine tightening torques ................................. 22.3 Capacities ....................................................... 22.3.1 Engine oil ................................................... 22.3.2 Coolant ....................................................... 22.3.3 Fuel ........................................................... 22.4 chassis ........................................................... 22.5 Electrical system.............................................. 22.6 Tires ............................................................... 22.7 fork ................................................................ 22.8 shock absorber ................................................ 22.9 chassis tightening torques................................. SUBSTANCES ............................................................ AUXILIARY SUBSTANCES ........................................... x x x x 18 19 20 21 22 23 24 6 140 142 144 144 145 147 147 149 150 150 152 153 156 160 160 161 164 164 164 165 165 166 167 167 168 169 174 178 25 STANDARDS .............................................................. 181 INDEX ............................................................................... 182 1 MEANS OF REPRESENTATION 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required. Indicates a page reference (more information is provided on the specified page). 1.2 Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name® Identifies a protected name. Brand™ Identifies a brand available on the open market. 7 2 SAFETY ADVICE 2.1 Use definition - intended use 8 KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is only authorized for operation on public roads in the homologated version. 2.2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. Info The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. 2 SAFETY ADVICE 2.3 Degrees of risk and symbols 9 Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. 2.4 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: 2 SAFETY ADVICE 10 1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases. 2 Removal or puncturing of any part of the intake system. 3 Lack of proper maintenance. 4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 2.5 Safe operation Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle. 2 SAFETY ADVICE 2.6 Protective clothing 11 Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.7 Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After you complete the repair or service work, check the operating safety of the vehicle. 2.8 Environment If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others. When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country. Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you. 2 SAFETY ADVICE 2.9 Owner's Manual 12 It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury. Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold. 3 IMPORTANT NOTES 3.1 Guarantee, warranty 13 The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. Additional information on the guarantee or warranty and the procedures involved can be found in the service record. 3.2 Operating and auxiliary substances Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual. 3.3 Spare parts, accessories For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you. The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com 3.4 Service A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components. Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. 3 IMPORTANT NOTES 14 It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle. 3.5 Figures The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text. 3.6 Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com 15 4 VIEW OF VEHICLE 4.1 View of vehicle, front left side (example) 16 601816-11 4 VIEW OF VEHICLE 1 Hand brake lever ( 2 Clutch lever ( 3 Handrails ( 4 Filler cap 5 Fork compression adjustment 6 Engine number ( 17 p. 23) p. 23) p. 38) p. 21) 7 Shift lever ( p. 39) 8 Side stand ( p. 40) 9 Seat release ( p. 37) 9 Compression damping of the shock absorber ( 10 Passenger footrests ( p. 38) p. 62) 4 VIEW OF VEHICLE 4.2 View of vehicle, rear right side (example) 18 601817-11 4 VIEW OF VEHICLE 1 Light switch ( p. 25) 1 Turn signal switch ( 1 Horn button ( 2 Ignition/steering lock ( 3 Function buttons ( 3 Indicator lamps ( 4 Emergency OFF switch ( 4 Electric starter button ( 5 Throttle grip ( 6 Fork rebound adjustment 7 Shock absorber, rebound adjustment 8 Foot brake lever ( 9 Level viewer, engine oil 10 Type label ( 11 Chassis number ( p. 25) p. 24) p. 27) p. 28) p. 29) p. 26) p. 26) p. 24) p. 40) p. 20) p. 20) 19 5 SERIAL NUMBERS 5.1 Chassis number 20 The chassis number 1 is stamped on the steering head on the right. 601858-10 5.2 Type label The type label 1 is located on the right side of the frame. B01289-10 5 SERIAL NUMBERS 5.3 Key number 21 The key number 1 can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 100179-10 5.4 Engine number The engine number 1 is stamped on the left side of the engine under the engine sprocket. 601860-10 5 SERIAL NUMBERS 5.5 Fork part number 22 The fork part number 1 is stamped on the inner side of the fork stub. 601861-10 5.6 Shock absorber part number The shock absorber part number 1 is on the left of the shock absorber. 601862-10 6 CONTROLS 6.1 Clutch lever 23 The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 601863-10 6.2 Hand brake lever The hand break lever 1 is fitted on the right side of the handlebar. The hand brake lever operates the front brake. 601864-10 6 CONTROLS 6.3 Throttle grip 24 The throttle grip 1 is fitted on the right side of the handlebar. 601864-11 6.4 Horn button The horn button 1 is fitted on the left side of the handlebar. Possible states • Horn button • Horn button 601865-12 in neutral position pressed – The horn is operated in this position. 6 CONTROLS 6.5 Light switch 25 The light switch 1 is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on. 601865-10 6.6 Turn signal switch The turn signal switch 1 is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal light, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal light, right, on – Turn signal switch pressed to the right. The turn signal switch returns automatically to the central position after use. 601865-11 To switch off the turn signal light, press the turn signal switch towards the switch case. 6 CONTROLS 6.7 Emergency OFF switch 26 The emergency OFF switch 1 is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started. Emergency OFF switch on – This position is necessary for operation as the ignition circuit is closed. 601866-10 6.8 Electric starter button The electric starter button 1 is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button 601866-11 in basic position pressed – In this position, the electric starter is actuated. 6 CONTROLS 6.9 Ignition/steering lock 27 The ignition/steering lock 1 is located in front of the seat. Possible states Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed. Ignition ON – In this position, the ignition circuit is closed and the engine can be started. 600825-01 6.10 Combination instrument 6.10.1 Overview Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed. The combination instrument is installed in front of the handlebar. The combination instrument is divided into 4 function areas. 1 Function buttons 2 Tachometer 3 Indicator lights 4 Display 400832-10 6 CONTROLS 6.10.2 Function buttons 28 You can change the display mode with the MODE button 1. Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2). Press the SET button 2 to reset the trip master 1 function (TRIP 1) and trip master 2 function (TRIP 2) to 0.0. Button 3 has no function. 400833-10 6.10.3 Tachometer The tachometer 1 shows the engine speed in revolutions per minute. The red marking 2 shows the excess speed range of the engine. 400834-10 6 CONTROLS 6.10.4 Indicator lamps 29 The indicator lamps offer additional information about the operating state of the motorcycle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idle speed indicator lamp lights up green – The transmission is shifted to idle. 401440-01 The high beam indicator lamp lights up blue – The high beam is switched on. The temperature warning lamp lights up red – The coolant temperature has reached a critical value. The low fuel warning lamp lights up yellow – The fuel level has reached the reserve mark. The display switches to TRIP F. The oil pressure warning lamp lights up red – The oil pressure is too low. FI warning lamp (MIL) lights up/flashes yellow – The OBD (on-board diagnosis) has detected an emission- or safety-critical error. The battery warning lamp lights up red – The voltage in the vehicle system is too low. 6 CONTROLS 6.10.5 Display 30 When you switch on the ignition, all display segments light up for a second as a function test. 400836-01 LEnGth Following the display function test, the LEnGth wheel circumference is shown for one second. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series production tire. The display then changes to the last selected mode. 400881-01 6 CONTROLS 6.10.6 Speed display 31 The speed 1 is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 6.10.7 Setting kilometers or miles Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary. 6 CONTROLS 32 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h. . 400839-01 6.10.8 Time The time is shown in area 1 of the display. Info After reconnecting the battery or changing the fuse, the time must be reset. 400838-11 6.10.9 Setting the clock Condition The motorcycle is stationary. 6 CONTROLS 33 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. – Press the MODE button to set the hour. . The time display begins to flash. 400838-01 – Press the SET button to set the minute. – Keep the MODE button and the SET button pressed simultaneously. The time is set. 6.10.10 ODO display In the ODO display mode, the total distance traveled is shown in kilometers or miles. Info This value is retained, even if the battery is disconnected and/or the fuse blows. 400839-01 6.10.11 Setting/resetting display TRIP 1 Info The TRIP 1 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again. 6 CONTROLS 34 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. . The TRIP 1 display is set to 0.0. 400840-01 6.10.12 Setting/resetting display TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again. – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 . 6 CONTROLS 35 6.10.13 TRIP F display If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 400842-01 6.10.14 Coolant temperature indicator The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temperature warning lamp lights up. Possible states • Engine cold – Up to four bars light up. • Engine warm – Five to eleven bars light up. • Engine hot – All twelve bars flash. 700124-01 6 CONTROLS 6.11 Opening the filler cap 36 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Lift the cover of filler cap 1 and insert the ignition key. – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a fuel tank breather. 601867-10 6 CONTROLS 6.12 Closing filler cap 37 – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover. 601868-01 6.13 Seat release The seat can be released using strap 1. 601869-10 6 CONTROLS 6.14 Handrails 38 The handrails 1 are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 601870-10 6.15 Passenger footrests The passenger footrests can be folded up and down. Possible states • Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. 601871-01 6 CONTROLS 6.16 Shift lever 39 The shift lever 1 is mounted on the left side of the engine. 601872-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 601872-11 6 CONTROLS 6.17 Foot brake lever 40 Foot brake lever 1 is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 601876-10 6.18 Side stand The side stand 1 is located on the left side of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system – see the riding instructions. 601873-10 Possible states • Side stand folded out – The vehicle can be supported on the side stand. The safety starting system is active. • Side stand folded in – This position is mandatory when riding the motorcycle. The safety starting system is inactive. 7 PREPARING FOR USE 7.1 Advice on first use 41 Danger Danger of accidents Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury Missing or poor protective clothing presents an increased safety risk. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels. – The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in. 7 PREPARING FOR USE 42 Warning Danger of accidents Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking. Info When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully. – Get to know the controls. – Adjust the basic position of clutch lever. ( – Adjust the basic position of hand brake lever. ( p. 84) p. 86) – Adjust the basic position of the foot brake lever. – Get used to handling the vehicle on a suitable piece of land before making a longer trip. Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – Run the engine in. ( 7.2 – x( p. 91) p. 42) Running in the engine During the running-in phase, do not exceed the specified engine speed. 7 PREPARING FOR USE 43 Guideline Maximum engine speed – During the first: 1,000 km (621.4 mi) 6,000 rpm After the first: 1,000 km (621.4 mi) 7,800 rpm Avoid fully opening the throttle! 7.3 Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack. – Mount and secure suitcase and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. – Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage. Maximum speed with baggage 130 km/h (80.8 mph) Warning Danger of accidents Risk of breakage of suitcase system. – If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload. 7 PREPARING FOR USE 44 Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed properly at regular intervals. Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload. – Adapt your speed according to your payload. Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 350 kg (772 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.) 8 RIDING INSTRUCTIONS 8.1 Performing checks and vehicle care when preparing for use Info Before each use, check the state and roadworthiness of the vehicle. Make sure that the vehicle is in perfect technical condition before use. – Check the engine oil level. ( p. 138) – Check the front brake fluid level. ( – Check the rear brake fluid level. ( – Check the front brake linings. ( – Check the rear brake linings. ( – Check the brake system function. – Check the coolant level. ( p. 128) – Check the chain for dirt. ( p. 76) – Check the chain tension. ( p. 78) – Check the tire condition. ( p. 104) – Check the tire air pressure. ( – Check the settings of all controls and ensure that they can be operated smoothly. – Check that the electrical equipment is functioning correctly. – Check that baggage is correctly secured. – Sit on the motorcycle and check the rear mirror setting. – Check the fuel level. p. 87) p. 92) p. 89) p. 94) p. 106) 45 8 RIDING INSTRUCTIONS 8.2 Starting 46 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged. – Never operate the vehicle with a discharged battery or without a battery. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. – Always warm up the engine at low engine speeds. – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to position ON . . After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time. – Shift gear to neutral. The green idling speed indicator lamp N lights up. – B00103-10 Press the electric starter button . 8 RIDING INSTRUCTIONS 47 Info Do not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start. Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again. This motorcycle is equipped with a safety starting system. You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged. If the side stand is folded out and you shift into gear and release the clutch lever, the engine stops. – 8.3 – Take the weight off the side stand and swing it back up with your foot as far as it will go. Starting off Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. 8.4 Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up. – Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. 8 RIDING INSTRUCTIONS 48 Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger. – The passenger must be able to hold himself or herself properly on the passenger seat, to hold onto the rider or to hold onto the handrails and place his or her feet onto the passenger footrests. Note the regulations governing the minimum age of passengers in your country. Warning Danger of accidents Danger of accidents caused by dangerous driving. – Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on. Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in. 8 RIDING INSTRUCTIONS 49 Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of accidents Lack of roadworthiness. – After a fall, check the vehicle as usual before preparing for use. Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Note Engine failure Overheating of engine. – If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If unusual noises arise during operation, stop immediately, park the vehicle properly, and contact an authorized KTM workshop. 8 RIDING INSTRUCTIONS 50 – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the 6 forward gears in the figure. The neutral or idle position is between the first and second gears. First gear is used for starting off or for steep inclines. The operating temperature is reached when 5 bars of the temperature indicator light up. 601872-11 – After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed but fuel consumption will be considerably lower. – Accelerate only up to a speed suitable for the road surface and weather conditions. When traveling in bends, do not shift, and accelerate very carefully. – To shift down, brake if necessary and close the throttle at the same time. – Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again. – If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the electric starter button. You do not have to shift into neutral. – Switch off the engine if you expect to be standing for a long time. – Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system. – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch. – If the FI warning lamp (MIL) lights up during a trip, stop immediately. When you shift to neutral, the FI warning lamp (MIL) starts to flash. 8 RIDING INSTRUCTIONS 51 Info From the flashing rhythm, you can derive a two-digit number, the so-called blink code. The blink code tells you which component has a fault. 8.5 Braking Warning Danger of accidents If you brake too hard, the wheels can lock. – Adapt your braking to the traffic situation and the road conditions. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system. – Clean or dry a dirty or wet brake system by riding and braking gently. Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking. Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. 8 RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. – To brake, release the throttle and operate the front and rear brakes simultaneously. – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overrev the engine. As a result, you will have to apply the brakes far less frequently and the brake system will not overheat. 8.6 Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the vehicle, lock the steering and remove the ignition key. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. 52 8 – RIDING INSTRUCTIONS 53 Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over. – Brake the motorcycle. – Shift gear to neutral. – Switch off the ignition by turning the ignition key to position OFF . Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine with the ignition key - the emergency OFF switch is intended for emergencies only. – Park the motorcycle on a firm surface. – Swing the side stand forward with your foot as far as it will go and lean the vehicle on it. – Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to position and turning it to position To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key. 8.7 Transport Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. . 8 RIDING INSTRUCTIONS 54 Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. – Switch off the engine and remove the ignition key. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 401448-01 8.8 Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. 8 RIDING INSTRUCTIONS 55 Note Material damage Premature clogging of the fuel filter. – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Switch off the engine. – Open the filler cap. ( – Fill the fuel tank with fuel up to measurement A. p. 36) Guideline Measurement A Total fuel tank capacity, approx. 400405-10 – Close the filler cap. ( 20 mm (0.79 in) 12 l (3.2 US gal) p. 37) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 176) 8 RIDING INSTRUCTIONS – 56 Press the SET button 2 for two seconds. The fuel level warning lamp 1 switches off. TRIP F is set to 0.0 and the display returns to the previous display mode. Info If you do not press the SET button 2, the reset takes place automatically after approx. three minutes. 400882-10 9 SERVICE SCHEDULE 9.1 Service schedule 57 K10N K100A K200A Check that the electrical equipment is functioning correctly. • • • Read out the fault memory using the KTM diagnostics tool. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • x Check the measured service values with the KTM diagnostics tool. Change the engine oil and filter, clean the oil screens. Check the front brake linings. ( p. 139) p. 89) p. 94) Check the rear brake linings. ( Check the brake discs. ( x( x p. 86) Check the brake lines for damage and leakage. Check the rear brake fluid level. ( p. 92) Check the free travel of the foot brake lever. ( p. 90) Check that the shock absorber and fork are leak tight. If necessary and depending on use, service the fork and shock absorber. Check the swingarm bearing. x Check the wheel bearing for play. Check the tire condition. ( Check the tire air pressure. ( Check the spoke tension. ( Check for rim run-out. x p. 104) p. 106) p. 107) x Check the chain, rear sprocket, engine sprocket, and chain guide. ( Check the chain tension. ( p. 80) p. 78) Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. Clean the dust boots of the fork legs. ( p. 71) x 9 SERVICE SCHEDULE Check the front brake fluid level. ( Bleed the fork legs. ( 58 p. 87) K10N K100A K200A • • • • • • • • p. 70) Check the steering head bearing play. Change the spark plug. • Check the valve clearance. • x Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing. • x Check the antifreeze and coolant level. ( p. 126) • Check the cables for damage and routing without sharp bends. x Check that the throttle cables are undamaged, routed without sharp bends and set correctly. Change the air filter. Clean the air filter box. Check the fuel pressure. • x x Check the CO adjustment with the KTM diagnostics tool. Check/rectify the fluid level of the hydraulic clutch. ( Check the screws and nuts for tightness. x p. 85) • x • • • • • • • • • • • • • • • • • Change the rear brake fluid. x Change the rear brake fluid. x Check the clutch. x Check the headlight setting. ( • • • p. 124) Check that the radiator fan is functioning properly. x Final check: Check the vehicle for roadworthiness and take a test ride. Read out the fault memory using the KTM diagnostics tool after a test ride. Make the service entry in KTM DEALER.NET and in the service record. x x • • • • • • • • • • • • • • • 9 SERVICE SCHEDULE K10N: Once after 1,000 km (621.4 mi) K100A: Every 10,000 km (6,214 mi) or annually or after every sporting use K200A: Every 20,000 km (12,428 mi) or every 2 years 59 10 TUNING THE CHASSIS 10.1 Fork/shock absorber 60 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table 1. You can find the table on the underside of the seat. 601888-10 10.2 These adjustments should be understood as a guideline and should always be the basis of your own personal suspension setting. Do not change the settings at random or by more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly at high speeds. Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws 1 clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. – 601886-10 Turn back counterclockwise by the number of clicks corresponding to the fork type. 10 TUNING THE CHASSIS 61 Guideline Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. – Turn adjusting screws 1 clockwise all the way. Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs. – 601877-10 Turn back counterclockwise by the number of clicks corresponding to the fork type. 10 TUNING THE CHASSIS 62 Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full load capacity 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.4 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly. The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more slowly. These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa. 10.5 Adjusting the low-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) 10 TUNING THE CHASSIS 63 Info The low-speed setting takes effect during the slow to normal compression of the shock absorber. – Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting 2! – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed 601878-10 Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.6 Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) 10 TUNING THE CHASSIS 64 Info The high-speed setting takes effect during the fast compression of the shock absorber. – Turn adjusting screw 1 clockwise all the way using a socket wrench. Info Do not loosen fitting 2! – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 601878-11 Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.7 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) 10 TUNING THE CHASSIS 65 – Turn adjusting screw 1 clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 601891-10 Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.8 Handlebar position In the upper triple clamp, there are 2 drill holes separated by a distance of A. Hole distance A 15 mm (0.59 in) The drill holes on the handlebar holder are centered and separated by a distance of B. Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in 4 different positions. In this way, the handlebar can be mounted in the position that is most comfortable for the rider. 601874-10 10 TUNING THE CHASSIS 10.9 Adjusting the handlebar position – 66 x Remove the four screws 1. Remove the handlebar clamps. Take off the handlebar and set it aside. Info Cover the motorcycle and attachments to protect them from damage. Do not kink the cables and lines. – Remove the two screws 2. Take off the handlebar holder. – Move the handlebar holder to the desired position. Mount and tighten the two screws 2. 601875-10 Guideline Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™ Info Position the handlebar holders evenly on the left and right. – Position the handlebar. Info Ensure that the cables and lines are routed correctly. – Position the handlebar clamps. Mount and evenly tighten the four screws 1. Guideline Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) 11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Stand the motorcycle upright on a level surface. – Raise the motorcycle in the area of the footrest bracket. – Secure the motorcycle against falling over. S00053-10 11.2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. 67 11 SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand and rest it on its side stand. – Remove the lift stand. 68 601873-11 11.3 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the adapter into the rear wheel stand and screw into the swingarm on both sides. Adapter (61029055110) Rear wheel stand (61029055400) – 601893-01 Position the motorcycle upright, align the stand and raise the motorcycle. 11 SERVICE WORK ON THE CHASSIS 11.4 Taking the motorcycle off of the rear wheel stand 69 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand. 601873-11 11.5 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 68) 11 SERVICE WORK ON THE CHASSIS 70 Main work – Move the handlebar to the straight-ahead position. Align the front wheel stand with the fork legs using the adapters. Front wheel stand (61029055300) Info Always raise the rear of the motorcycle first. 601892-01 11.6 – Raise the front of the motorcycle. Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the front wheel stand. 11.7 Bleeding the fork legs Preparatory work – Lean the motorcycle on the side stand. 11 SERVICE WORK ON THE CHASSIS 71 Main work – Briefly loosen bleeder screws 1. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs. 601879-10 11.8 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( – Remove the fork protector. ( p. 67) p. 72) Main work – Push dust boots 1 on both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind the dust boots can start to leak. Warning L00350-10 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. 11 SERVICE WORK ON THE CHASSIS – 72 Clean and oil the dust boots and inside fork tube of both fork legs. Universal oil spray ( p. 180) – Push the dust boots back into their normal position. – Remove excess oil. Finishing work – Install the fork protector. ( 11.9 p. 73) – Remove the motorcycle from the lift stand. ( – Remove screws 1 and take off clamp. – Remove screws 2 on left fork leg. Remove the fork protector. – Remove the screws on the right fork leg. Remove the fork protector. p. 67) Removing the fork protector S00054-12 11 SERVICE WORK ON THE CHASSIS 11.10 Installing the fork protector – 73 Position the fork protection on the left fork leg. Mount and tighten screws 1. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line and cable harness. Put the clamp on, mount and tighten screws 2. – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis S00054-13 11.11 M6 Removing the seat 601869-10 – Pull on strap 1 and raise the rear of the seat at the same time. – Pull back the seat and lift it off. 10 Nm (7.4 lbf ft) 11 SERVICE WORK ON THE CHASSIS 11.12 Mounting the seat 74 601887-10 – Hook slot 1 of the seat onto screw 2, press the rear downward and at the same time push it forward. – Push locking pin 3 into lock housing 4 and push the back of the seat down until the locking pin locks in place with an audible click. – Finally, check that the seat is correctly mounted. 11.13 Removing the air filter x Preparatory work – Remove the seat. ( p. 73) Main work – Remove screws 1. Take off air filter box top 2. 601882-10 11 SERVICE WORK ON THE CHASSIS 75 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Remove air filter 3. 601880-10 11.14 Installing the air filter x Main work – Clean the air filter box. – Mount air filter 1. Info The air filter must lie flush against the air filter box along the entire sealing surface A. If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage. 601881-10 – Hook air filter box top 2 into the front of the air filter box and swing down. 11 SERVICE WORK ON THE CHASSIS – 76 Mount and tighten screws 3. Guideline Screw, air filter box top M6 601882-11 Finishing work – Mount the seat. ( 11.15 p. 74) Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – 400678-01 Clean the chain. ( p. 77) 2 Nm (1.5 lbf ft) 11 SERVICE WORK ON THE CHASSIS 11.16 Cleaning the chain 77 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( – p. 178) After drying, apply chain spray. Chain lube for road use ( 400725-01 p. 178) 11 SERVICE WORK ON THE CHASSIS 11.17 Checking the chain tension 78 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary. – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upward at a distance B from the chain sliding guard and determine the chain tension A. Info The upper chain section C must be taut. Chain wear is not always even. Repeat this measurement at different chain positions. » Chain tension 5 mm (0.2 in) Distance to chain sliding guard 30 mm (1.18 in) If the chain tension does not meet specifications: – 100249-10 Adjust the chain tension. ( p. 79) 11 SERVICE WORK ON THE CHASSIS 11.18 Adjusting the chain tension 79 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary. Preparatory work – Check the chain tension. ( p. 78) 11 SERVICE WORK ON THE CHASSIS 80 Main work – Loosen nut 1. – Loosen nuts 2. – Adjust the chain tension by turning adjusting screws 3 on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws 3 so that the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks C. The rear wheel is then correctly aligned. Info The upper chain section must be taut. Chain wear is not always even. Repeat this measurement at different chain positions. – Tighten nuts 2. – Make sure that the chain adjusters 4 are installed correctly on adjusting screws 3. – 601883-10 11.19 Tighten nut 1. Guideline Nut, rear wheel spindle M25x1.5 Check the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 68) 90 Nm (66.4 lbf ft) 11 SERVICE WORK ON THE CHASSIS 81 Main work – Shift the transmission to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. x Info The engine sprocket, rear sprocket, and chain should always be replaced together. 100132-10 – Pull on the upper section of the chain with the specified weight A. Guideline Weight of chain wear measurement A 0 – 15 kg (33 lb.) Measure distance B of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions. Maximum distance B at the longest chain section » If the distance B is greater than the specified measurement: – B 0 1 2 3 0 A 272 mm (10.71 in) Replace the chain. x Info 16 17 18 400987-10 When the chain is replaced, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets. 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – – 82 Replace the chain sliding guard. x Check that the chain sliding guard is firmly seated. » If the chain sliding guard is loose: – Tighten the chain sliding guard. Guideline Screw, chain sliding guard 401170-01 M6 8 Nm (5.9 lbf ft) Loctite® 243™ 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – – 83 Change the chain sliding piece. x Check that the chain sliding piece is firmly seated. » If the chain sliding piece is loose: – Tighten the chain sliding piece. Guideline Screw, chain sliding piece M8 401171-01 – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – 400985-01 Change the chain guide. x 15 Nm (11.1 lbf ft) 11 SERVICE WORK ON THE CHASSIS – 84 Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 601884-01 Finishing work – Take the motorcycle off of the rear wheel stand. ( 11.20 p. 69) Adjusting basic position of clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding! 11 SERVICE WORK ON THE CHASSIS 85 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw 1. – When adjusting the clutch lever, make sure to leave a minimum clearance to other parts of the vehicle. Guideline Minimum clearance 5 mm (0.2 in) 601885-10 11.21 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1. – Remove cover 2 with membrane 3. – Check the fluid level. Fluid level under top level of container » If the level of the coolant does not meet specifications: – Correct the fluid level of the hydraulic clutch. Hydraulic fluid (15) ( 100281-10 – 4 mm (0.16 in) p. 176) Position the cover with the membrane. Mount and tighten the screws. 12 BRAKE SYSTEM 12.1 Adjusting the basic position of the hand brake lever 86 – Adjust the basic setting of the hand brake lever to your hand size by turning adjusting wheel 1. Info Pull the hand brake lever forward and turn the adjusting wheel. Do not make any adjustments while riding! 601894-10 12.2 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement A. Info Wear reduces the thickness of the brake disc at the contact surface 1 of the brake disc. Brake discs - wear limit 100135-10 Front 4.0 mm (0.157 in) Rear 4.5 mm (0.177 in) 12 BRAKE SYSTEM 87 » If the brake disc thickness is less than the specified value: – – » If damage, cracks, or deformation are visible on the brake disc: – 12.3 Replace the brake disc. Check the front and rear brake discs for damage, cracks, and deformation. Replace the brake disc. Checking the front brake fluid level Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Check the brake fluid level in the viewer 1. » When the brake fluid level drops below the MIN mark: – 601908-10 Add front brake fluid. x( p. 88) 12 BRAKE SYSTEM 12.4 Adding front brake fluid 88 x Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. 12 BRAKE SYSTEM 89 Preparatory work – Check the front brake linings. ( p. 89) Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1. – Remove cover 2 with membrane 3. – Add brake fluid to level A. Guideline Measurement of A Brake fluid DOT 4 / DOT 5.1 ( – 100254-10 5 mm (0.2 in) p. 174) Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 12.5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly. 12 BRAKE SYSTEM 90 – Check the brake linings for minimum thickness A. ≥ 1 mm (≥ 0.04 in) Minimum thickness A » If the minimum thickness is less than specified: – – Change the front brake linings. x Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the front brake linings. x 601895-10 12.6 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications. – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A. Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info You will know that contact has been made with the foot brake cylinder piston when there is increased resistance when you activate the foot brake lever. 601896-10 » If the free travel does not meet specifications: – Adjust the basic position of the foot brake lever. x( p. 91) 12 BRAKE SYSTEM 12.7 Adjusting the basic position of the foot brake lever 91 x Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications. – Loosen fitting 3 on foot brake cylinder 4. – To adjust the basic position of the foot brake lever individually, loosen nut 1 and turn screw 2 accordingly. Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns. – Position foot brake cylinder 4 so that the foot brake lever has the necessary free travel. Hold screws 3 in place and tighten the nuts. Guideline Screw connection, foot brake cylinder 601897-10 M6 – Check the free travel of the foot brake lever. ( – Tighten nut 1. 10 Nm (7.4 lbf ft) p. 90) 12 BRAKE SYSTEM 12.8 Checking rear brake fluid level 92 Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking 1: – Add rear brake fluid. x( p. 92) 601898-10 12.9 Adding rear brake fluid x Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) 12 BRAKE SYSTEM 93 Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work – Check the rear brake linings. ( p. 94) 12 BRAKE SYSTEM 94 Main work – Stand the vehicle upright. – Remove screw cap 1 with the washer and membrane 2. – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( – p. 174) Mount the screw cap with the washer and membrane. Info 601899-10 12.10 Clean up overflowed or spilt brake fluid immediately with water. Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly. 12 BRAKE SYSTEM 95 – Check the brake linings for minimum thickness A. ≥ 1 mm (≥ 0.04 in) Minimum thickness A » If the minimum thickness is less than specified: – – » x If there is wear or tearing: – 601900-10 Change the rear brake linings. Check the brake linings for damage and cracking. Change the rear brake linings. x 13 WHEELS, TIRES 13.1 Removing front wheel 96 x Preparatory work – Raise the motorcycle with the rear wheel stand. ( – Raise the motorcycle with the front wheel stand. ( p. 68) p. 69) Main work – Remove screws 1 and spacers 2. – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc. Pull the brake caliper carefully back from the brake disc and hang it to one side. Info Do not pull the handbrake lever when the brake caliper is removed. 601901-10 – Loosen screws 3 and 4. – Unscrew screw 3 about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw 3. Warning Danger of accidents Reduced braking effect caused by damaged brake discs. – 601902-10 – Always lay the wheel down in such a way that the brake discs are not damaged. Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. 13 WHEELS, TIRES 97 – Remove distance bushings 5. S00083-11 13.2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Replace the wheel bearing. Long-life grease ( – S00083-10 x Clean and grease the shaft seal rings and bearing surface of the distance bushings 1. Insert the spacers. p. 179) 13 WHEELS, TIRES 98 – Clean and grease the thread of the wheel spindle and screw 2. Long-life grease ( – p. 179) Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and tighten screw 2. Guideline Screw, front wheel spindle 601901-11 M24x1.5 45 Nm (33.2 lbf ft) – Position the brake caliper and check that the brake linings are seated correctly. – Position spacers 3. Mount screws 4 but do not tighten. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in the activated position. – Fully tighten screws 4. The brake caliper straightens. Guideline Screw, front brake caliper – M10x1.25 Remove the fixation of the hand brake lever. 45 Nm (33.2 lbf ft) Loctite® 243™ 13 WHEELS, TIRES 99 – Take the motorcycle off of the front wheel stand. ( – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Tighten screws 5. p. 70) Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) 601886-11 13.3 Removing rear wheel Finishing work – Take the motorcycle off of the rear wheel stand. ( p. 69) Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 68) x Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. 601913-10 – Remove nut 1. Remove chain adjuster 2. – Holding the rear wheel, withdraw the wheel spindle 3. 13 WHEELS, TIRES 100 – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Reduced braking effect caused by damaged brake discs. – – 601903-01 13.4 Installing the rear wheel Always lay the wheel down in such a way that the brake discs are not damaged. Take the rear wheel out of the swing arm. Info Do not operate the foot brake when the rear wheel is removed. x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work – Check the rear hub rubber dampers. x( p. 102) 13 WHEELS, TIRES 101 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – – Replace the wheel bearing. Long-life grease ( – p. 179) Clean and grease the thread of the wheel spindle and nut 3. Long-life grease ( 601904-10 x Remove the bushing 1. Clean and grease the roll surfaces of the bushing and the shaft seal ring 2. p. 179) – Install the rubber damper and rear sprocket carrier in the rear wheel. – Position the rear wheel. The brake linings are correctly positioned. 13 WHEELS, TIRES 102 – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket. – Mount the wheel spindle, chain adjusters and nuts. Guideline In order that the rear wheel is correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks A. Info Mount the left and right chain adjusters 4 in the same position. – Tighten nut 3. Guideline Nut, rear wheel spindle – M25x1.5 90 Nm (66.4 lbf ft) Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. 601883-11 Finishing work – Take the motorcycle off of the rear wheel stand. ( 13.5 Checking the rear hub rubber dampers p. 69) x Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. 13 WHEELS, TIRES 103 Preparatory work – Raise the motorcycle with the rear wheel stand. ( – Remove the rear wheel. x( p. 68) p. 99) Main work – Check bearing 1. » If the bearing is damaged or worn: – – Replace the bearings. x Check rubber dampers 2 of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: – Change all rubber dampers in the rear hub. 601906-10 – Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub. – To check play A, hold the rear wheel tight and try to rotate the rear sprocket with your hand. Info Measure the play on the outside of the rear sprocket. Play in rubber dampers, rear wheel 601905-10 » If play A is larger than the specified value: – Change all rubber dampers in the rear hub. Finishing work – Install the rear wheel. – ≤ 5 mm (≤ 0.2 in) x( p. 100) Take the motorcycle off of the rear wheel stand. ( p. 69) 13 WHEELS, TIRES 13.6 Checking the tire condition 104 Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels. – The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in. Info The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle. Worn tires have a negative effect on riding behavior, especially on wet surfaces. 13 WHEELS, TIRES 105 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tires exhibit cuts, run-in objects or other damage: – – Change the tires. Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth 400602-10 » If the tread depth is less than the minimum permissible depth: – – ≥ 2 mm (≥ 0.08 in) Change the tires. Check the age of the tires. Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years. » If a tire is more than 5 years old: – Change the tires. 13 WHEELS, TIRES 13.7 Tubeless tire system 106 This vehicle makes use a tubeless tire system in which a tubeless sealing profile 1 is used instead of the conventional tube. The advantages of the tubeless system lie in the absence of danger from a faulty tube. This greatly reduces the risk of a sudden loss in pressure. The masses and moments of inertia of these wheels are smaller than in conventional spoke wheels with a tube. This results in better handling and riding comfort. The rigid rim design results in a spoke wheel that is almost entirely maintenance-free. KTM recommends that the tubeless sealing profile be changed after 5 years at the latest, regardless of the actual state of wear. 301978-10 13.8 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. 13 WHEELS, TIRES 107 – Remove the protection cap. – Check tire air pressure when tires are cold. Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded 400695-01 » 13.9 2.0 bar (29 psi) Rear 2.2 bar (32 psi) If the tire pressure does not meet specifications: – – Front Correct tire pressure. Mount the protection cap. Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. 13 WHEELS, TIRES 108 – Briefly strike each spoke with a screwdriver blade. Info The frequency of the tone is a function of the spoke length and spoke diameter. If you hear different tone frequencies from individual spokes of the same length and thickness, this is an indication of different spoke tensions. You should hear a high note. 400694-01 » If the spoke tensions differ: – Correct the spoke tension. x 14 ELECTRICAL SYSTEM 14.1 Removing the battery 109 x Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open flames. Charge only in well-ventilated areas. – In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 73) Main work – Disconnect the negative (minus) cable of the battery. 601907-10 – Pull plug 1 off upward. – Remove screws 2. – Pull the retaining bracket 3 of the battery forward and remove it. – Take off the positive pole cover 4. – Disconnect the positive (plus) cable of the battery. – Push the wiring harness to the side and pull the battery out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged. The vehicle is therefore no longer roadworthy. 14 ELECTRICAL SYSTEM 14.2 Installing the battery 110 x Main work – Slide the battery into the battery holder. Info The battery terminals must be at the rear. – Attach the positive cable and mount positive terminal cover 1. – Position retaining bracket 2. – Mount and tighten screws 3. 601907-11 Guideline Remaining screws, chassis – Plug in connector 4. – Attach the minus cable . Finishing work – Mount the seat. ( – Set the clock. ( p. 74) p. 32) M6 10 Nm (7.4 lbf ft) 14 ELECTRICAL SYSTEM 14.3 Recharging the battery 111 x Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open flames. Charge only in well-ventilated areas. – In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician. Warning Environmental hazard The battery contains elements that are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. 14 ELECTRICAL SYSTEM 112 Info Even when there is no load on the battery, it still loses power steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity. If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately. If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery. The battery is maintenance-free, which means that the acid level does not need to be checked. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( – Remove the battery. p. 73) x( p. 109) 14 ELECTRICAL SYSTEM 113 Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid 1. Charge the battery with a maximum of 10% of the capacity specified on the battery housing 2. – Switch off and disconnect the charger after charging. Guideline The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use 100151-10 Finishing work – Install the battery. – Mount the seat. ( – Set the clock. ( x( p. 110) p. 74) p. 32) 3 months 14 ELECTRICAL SYSTEM 14.4 Changing the main fuse 114 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 73) Main work – Remove protection covers 1. C00185-10 14 ELECTRICAL SYSTEM 115 – Remove a defective main fuse 2 with needle nose pliers. – Install a new main fuse. Fuse (58011109130) ( p. 166) Info A reserve fuse 3 is located in the starter relay. C00186-10 – Check the functioning of the electrical equipment. – Mount the protection covers. Finishing work – Mount the seat. ( – 14.5 Set the clock. ( p. 74) p. 32) Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 73) 14 ELECTRICAL SYSTEM 116 Main work – Open fuse box cover 1. C00185-11 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument Fuse 2 - 10 A - clock, ignition (EFI control unit) Fuse 3 - 10 A - EPT control unit Fuse 4 - 10 A - fuel pump Fuse 5 - 10 A - radiator fan Fuse 6 - 10 A - horn, brake light, turn signal Fuse 7 - 15 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 8 - 10 A - for supplementary equipment (accessories connected with ignition switch) Fuse 9 - 10 A - for accessories (permanent positive) Fuse 10 - not used Fuse SPARE - 10 A/15 A - spare fuses Info A defective fuse is indicated by a burned-out fuse wire A. 600606-10 14 ELECTRICAL SYSTEM 117 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Replace with a spare fuse of the right rating. Fuse (75011088010) ( p. 166) Fuse (75011088015) ( p. 166) Tip Put a new spare fuse in the fuse box for future use if needed. – Check the function of power consumers. – Close the fuse box cover. Finishing work – Mount the seat. ( 14.6 p. 74) Removing the headlight mask with the headlight Preparatory work – Switch off all power consumers and switch off the engine. 14 ELECTRICAL SYSTEM 118 Main work – Cover the fender with a cloth to protect it from damage. – Remove screws 1 on both sides. – Tip the headlight mask forward. – Disconnect the connectors of turn signals 2 and headlight 3. – Remove the headlight mask. 601909-10 601910-10 14 ELECTRICAL SYSTEM 14.7 Installing the headlight mask with the headlight 119 Main work – Connect the connectors of headlight 1 and turn signal lights 2. – Check lighting function. – Remove the cloth from the fender and position the headlight mask. 601910-11 Holding lugs 3 reach into the headlight mask. 601911-10 14 ELECTRICAL SYSTEM 120 – Position groove 4 on counterpiece 5. – Position brake line guide 6. Mount and tighten screws 7. 601912-10 Guideline Screw, headlight mask M5 5 Nm (3.7 lbf ft) 601909-11 Finishing work – Check the headlight setting. ( 14.8 p. 124) Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. 14 ELECTRICAL SYSTEM 121 Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 117) Main work – Pull off connector 1. – Take off protection cap 2 of the headlight bulb. – Detach spring bar 3. – Remove headlight bulb 4. – Insert a new headlight bulb into the headlight housing. 600610-10 Headlight (H4 / socket P43t) ( p. 166) – Fix the headlight bulb in the headlight using the spring bar. – Mount the protection cap. Attach the connector. 600611-10 Finishing work – Install the headlight mask with the headlight. ( – Check the headlight setting. ( p. 124) p. 119) 14 ELECTRICAL SYSTEM 14.9 Changing the parking light bulb 122 Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( Main work – Remove protection cap 1. 600610-12 p. 117) 14 ELECTRICAL SYSTEM – 123 Pull bulb socket 2 out of the reflector. – Pull parking light bulb 3 out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1x9.5d) ( – Insert the bulb socket in the reflector. – Insert the protection cap. p. 167) 600612-10 Finishing work – Install the headlight mask with the headlight. ( – 14.10 Check the headlight setting. ( p. 119) p. 124) Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. 14 ELECTRICAL SYSTEM 124 Main work – Remove the screw on the rear of the turn signal housing. – Carefully swing turn signal glass 1 forward and take it off. – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket. Info Do not touch the reflector with your fingers, and keep it free from grease. 100160-10 – Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops. Turn signal (RY10W / socket BAU15s) ( p. 167) – Position the turn signal glass. – Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten the screw slightly. Finishing work – Check the turn signal system function. 14.11 Checking the headlight setting – Stand the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance B under the first mark. Guideline Distance B – 5 cm (2 in) Position the vehicle vertically at a distance A in front of the wall. Guideline 400726-10 Distance A 5 m (16 ft) 14 ELECTRICAL SYSTEM 125 – The rider, with luggage and a passenger if applicable, now sits down on the motorcycle. – Switch on the low beam. – Check the headlight setting. For a ready-to-operate motorcycle with a rider, and with luggage and a passenger if applicable, the light-dark boundary must lie exactly on the lower mark. » If the boundary between light and dark does not meet specifications: – 14.12 Adjust the headlight range. ( p. 125) Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 124) Main work – Turn adjusting screw 1 to adjust the headlight range. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (instructions on how to apply the mark: Checking the headlight setting). Info C00193-10 Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range. If you have a heavy payload, you will need to correct the headlight range. 15 COOLING SYSTEM 15.1 Cooling system 126 The water pump 1 in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap 2. The heat expansion causes the surplus coolant to flow into the compensating tank 3. When the temperature falls, this surplus coolant is sucked back into the cooling system. This permits the specified coolant temperature without causing any malfunctions. 125 °C (257 °F) C00192-10 Cooling takes place by means of the air stream and a radiator fan 4, which is controlled by a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 400407-10 15.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water. 15 COOLING SYSTEM 127 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Remove the cap of compensating tank 1. – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – – Correct the antifreeze of the coolant. Check the coolant level in the compensating tank. C00188-11 The coolant level must be within the range shown in the figure. » If the coolant level does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 174) Alternative 2 Coolant (mixed ready to use) ( – Mount the cap of the compensating tank. p. 174) 15 COOLING SYSTEM 128 – Screw off the radiator cap 2. – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – – Correct the antifreeze of the coolant. Check the coolant level in the radiator. The radiator must be completely filled. C00190-11 » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p. 174) Alternative 2 Coolant (mixed ready to use) ( – 15.3 p. 174) Mount the radiator cap. Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water. 15 COOLING SYSTEM 129 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Check the coolant level in the compensating tank 1. The coolant level must be within the range shown in the figure. » If the coolant level does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( C00188-11 p. 174) Alternative 2 Coolant (mixed ready to use) ( – p. 174) Screw off the radiator cap 2 and check the coolant level in the radiator. The radiator must be completely filled. » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( C00190-11 p. 174) 15 COOLING SYSTEM 130 Alternative 2 Coolant (mixed ready to use) ( – 15.4 Draining the coolant p. 174) Mount the radiator cap. x Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water. Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw 1. Take off the radiator cap. – Completely drain the coolant. – Mount screw 1 with a new seal ring and tighten it. Guideline Plug, drain hole of water pump C00191-10 M10x1 15 Nm (11.1 lbf ft) 15 COOLING SYSTEM 15.5 Filling/bleeding the cooling system 131 x Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children. – Stand the motorcycle on its side stand on a horizontal surface. – Remove radiator cap 1. – Refill the coolant. C00190-10 Alternative 1 Coolant ( p. 174) Alternative 2 Coolant (mixed ready to use) ( – C00189-10 p. 174) Fill the radiator completely with coolant. Mount radiator cap 1. 15 COOLING SYSTEM 132 – Remove the cap from compensating tank 2 and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – C00188-10 When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. – Start the engine and run it until the 5th bar of the temperature indicator lights up. – Switch off the engine and allow it to cool down. – After the engine has cooled down, check the coolant level in the radiator and in the compensating tank again and add more coolant if necessary. – Check the coolant level. ( p. 128) 16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable 133 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play » 3… 5 mm (0.12… 0.2 in) If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable. x( p. 133) Danger 400192-10 Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. » If the idle speed changes: – 16.2 Adjusting the play in the throttle cable Adjust the play in the throttle cable. x Preparatory work – Remove the seat. ( p. 73) – Take off the side cover. – Check the routing of the throttle cable. x( p. 133) 16 TUNING THE ENGINE 134 Main work – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut 1. – Set the play in the throttle cable by turning the adjusting screw 2. Guideline Throttle cable play C00187-10 16.3 – 3… 5 mm (0.12… 0.2 in) Tighten counter nut 1. Adjusting the engine characteristic Preparatory work – Switch off the ignition by turning the ignition key to position OFF – Remove the seat. ( . p. 73) Main work – Pull the Map‑Select switch and holder 1 upward off of the retaining bracket. – C00185-12 Pull the Map‑Select switch out of the holder. 16 TUNING THE ENGINE – 135 Turn the adjusting wheel until the desired digit is next to marking 2. Set the Map‑Select switch to Soft. – Set the adjusting wheel to position 1. Soft – reduced homologated peak performance for better driveability. Set the Map‑Select switch to Advanced. – Set the adjusting wheel to position 2. Advanced – homologated performance with extremely direct responsiveness. 601802-10 Set the Map‑Select switch to Standard. – Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9. Standard – homologated performance with balanced responsiveness. Set the Map‑Select switch to poor fuel quality. – Set the adjusting wheel to position 0. Poor fuel quality – homologated performance is reduced in accordance with the fuel quality, use for no more than 1 tank of fuel – Position the Map‑Select switch in the holder. – Slide the Map‑Select switch with the holder downward onto the retaining bracket. Finishing work – Mount the seat. ( p. 74) 16 TUNING THE ENGINE 16.4 Checking the basic position of the shift lever – 136 Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot » A 0 If the distance does not meet specifications: – Adjust the basic position of the shift lever. 400692-10 16.5 Adjusting the basic position of the shift lever – C00184-10 10… 20 mm (0.39… 0.79 in) x Remove screw 1 and take off shift lever 2. x( p. 136) 16 TUNING THE ENGINE 137 – Clean gear teeth A of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure. – C00183-10 Mount and tighten the screw. Guideline Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™ 17 SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level 138 Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer. » C00182-10 If the engine oil level is not at the specified level: – Add the engine oil. ( p. 145) 17 SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – – – – – 139 x Drain the engine oil. x ( p. 139) Remove the oil filter. x ( p. 140) Clean the oil screens. x ( p. 142) Install the oil filter. x ( p. 144) Fill up with engine oil. x ( p. 144) 601022-10 17.3 Draining the engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Drain the engine oil only when the engine is warm. 17 SERVICE WORK ON THE ENGINE 140 – Place a suitable container under the engine. – Remove the oil drain plug 1 with the magnet and seal ring. – Completely drain the engine oil. – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. 100200-10 Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 100201-01 17.4 Removing the oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. 17 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preparatory work – Place a suitable container under the engine. Main work – Remove screws 1. Remove the oil filter cover 2 with the O-ring. – Pull oil filter 3 out of the oil filter housing. Circlip pliers reverse (51012011000) 100202-10 – Remove screws 4. Take off the oil filter cover 5 with the O-ring. – Pull oil filter 6 out of the oil filter housing. Circlip pliers reverse (51012011000) C00181-10 – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. 141 17 SERVICE WORK ON THE ENGINE 17.5 Cleaning the oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preparatory work – Place a suitable container under the engine. Main work – Remove screw plug 1 with oil screen 2 and the O-rings. 100205-10 142 17 SERVICE WORK ON THE ENGINE 143 – Remove screw plug 3 with oil screen 4 and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. – Position oil screen 2 with the O-rings. – Mount and tighten screw plug 1 with the O-ring. 100206-10 Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 100207-10 – Position oil screen 4 with the O-rings. – Mount and tighten screw plug 3 with the O-ring. Guideline Plug, oil screen 100208-10 M20x1.5 15 Nm (11.1 lbf ft) 17 SERVICE WORK ON THE ENGINE 17.6 Installing the oil filter 144 x – Insert oil filters 1 and 2. – Oil the O-rings of the oil filter covers. Mount oil filter covers 3 and 4. – Mount and tighten the screws. Guideline Screw, oil filter cover M5 6 Nm (4.4 lbf ft) C00180-10 17.7 Filling up with engine oil x Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove filler plug with O-ring 1 from the clutch cover and add engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 175) Alternative engine oil – C00179-10 Refit plug with O-ring 1 and tighten it. Engine oil (SAE 10W/50) ( p. 175) 17 SERVICE WORK ON THE ENGINE 145 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and check that it is oil-tight. Finishing work – Check the engine oil level. ( 17.8 p. 138) Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 10W/60) (00062010035) ( Engine oil (SAE 10W/50) ( p. 175) p. 175) Info For optimal performance of the engine oil, do not mix different types of engine oil. If appropriate, change the engine oil. C00179-10 – Install and tighten the oil filler plug 1 with the O-ring. 17 SERVICE WORK ON THE ENGINE 146 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Start the engine and check that it is oil-tight. Finishing work – Check the engine oil level. ( p. 138) 18 CLEANING, CARE 18.1 Cleaning the motorcycle 147 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info If you clean the motorcycle regularly, its value and appearance will be maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning. – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p. 179) Info 401061-01 Clean the vehicle using a soft sponge and warm water containing normal motorcycle cleaner. Never apply motorcycle cleaner to the dry vehicle; always rinse with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water enhances the corrosive effects of salt. 18 CLEANING, CARE 148 – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the plug from the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system. – – Clean or dry a dirty or wet brake system by riding and braking gently. After cleaning, ride a short distance until the engine reaches operating temperature. Info The heat produced causes water at inaccessible locations in the engine and brake system to evaporate. – Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( – Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials. p. 77) Cleaning and preserving materials for metal, rubber and plastic ( – Treat all painted parts with a mild paint polish. High-luster polish for paint ( – p. 178) p. 179) Treat all plastic parts and powder-coated parts with a mild cleaning and care agent. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 179) – Lubricate the ignition/steering lock. 18 CLEANING, CARE 149 Universal oil spray ( 18.2 p. 180) Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. – Clean the motorcycle. ( – Clean the brake system. p. 147) Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed. After use on salted roads, clean the motorcycle thoroughly with cold water and dry it properly. 401060-01 – Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance. Info To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs. – Clean the chain. ( p. 77) 19 STORAGE 19.1 Storage 150 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children. Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. – Clean the motorcycle. ( – Change the engine oil and filter, clean the oil screens. – Check the antifreeze and coolant level. ( – When refueling for the last time before taking the motorcycle out of service, add fuel additive. Fuel additive ( p. 147) x( p. 139) p. 126) p. 178) – Ride the motorcycle until the low fuel warning lamp lights up and the display changes to TRIP F so that you can fill up with fresh fuel when you take the motorcycle back into service. – Check the tire air pressure. ( 401058-01 – Remove the battery. – Recharge the battery. x( x( p. 106) p. 109) p. 111) 19 STORAGE 151 Guideline Storage temperature of battery without direct sunshine – 0… 35 °C (32… 95 °F) Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( – Raise the motorcycle with the front wheel stand. ( – Cover the motorcycle with a tarp or cover that is permeable to air. p. 68) p. 69) Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. 19 STORAGE 19.2 Preparing for use after storage 152 401059-01 – Take the motorcycle off of the front wheel stand. ( – Take the motorcycle off of the rear wheel stand. ( – Recharge the battery. x( p. 70) p. 69) p. 111) – Install the battery. – Set the clock. ( – Refuel. ( – Perform checks and vehicle care when preparing for use. ( – Take a test ride. x( p. 110) p. 32) p. 54) p. 45) 20 TROUBLESHOOTING 153 Faults Possible cause Action The engine does not turn when the starter button is pressed Operating error – Carry out the start procedure. ( Battery is discharged – Recharge the battery. Fuse 1, 2, 3 or 4 is blown – Change the fuses of individual power consumers. ( p. 115) Engine turns only if the clutch lever is drawn Engine turns but does not start. x( p. 111) Main fuse burned out – Change the main fuse. ( No ground connection present – Check the ground connection. The vehicle is in gear – Shift gear to neutral. The vehicle is in gear and the side stand is folded out – Shift gear to neutral. p. 46) p. 114) Operating error – Carry out the start procedure. ( Fuse 4 blown – Change the fuses of individual power consumers. ( p. 115) Coupling of fuel hose connection not connected – Reconnect coupling of fuel hose connection. Defect in fuel injection system – Read out the fault memory using the KTM diagnostics tool. Air filter is very dirty – Remove the air filter. p. 46) x Engine has too little power. – Engine overheats. x ( p. 74) Install the air filter. x ( p. 75) Check the fuel pressure. x Read out the fault memory using the KTM diagnostics tool. x Fuel filter is very dirty – Defect in fuel injection system – Too little coolant in cooling system – Check the cooling system for leakage. – Check the coolant level. ( – Clean radiator fins. Radiator fins very dirty p. 128) 20 TROUBLESHOOTING 154 Faults Possible cause Action Engine overheats. Foam formation in cooling system – Drain the coolant. – Fill/bleed the cooling system. Buckled or damaged radiator hose – Change the radiator hose. Thermostat is faulty – Check the thermostat. Fuse 5 blown – Change the fuses of individual power consumers. ( p. 115) Defect in radiator fan system – Check the radiator fan system. Air in cooling system – FI warning lamp (MIL) lights/flashes Defect in fuel injection system – Engine dies during the journey Lack of fuel – Refuel. ( Fuse 1, 2 or 4 blown – Change the fuses of individual power consumers. ( p. 115) Engine vent hose bent – Route the vent hose without bends or change it if necessary. Engine oil level too high – Check the engine oil level. ( Engine oil too thin (low viscosity) – Change the engine oil and filter, clean the oil screens. ( p. 139) Headlight and parking light are not functioning Fuse 7 blown – Change the fuses of individual power consumers. ( p. 115) Turn signal, brake light and horn not functioning Fuse 6 blown – Change the fuses of individual power consumers. ( p. 115) Time is not (correctly) displayed Fuse 2 blown – Change the fuses of individual power consumers. ( p. 115) – Set the clock. ( High oil consumption x( p. 130) x( p. 131) x x x Fill/bleed the cooling system. x ( p. 131) Read out the fault memory using the KTM diagnostics tool. x p. 54) p. 138) x p. 32) 20 TROUBLESHOOTING 155 Faults Possible cause Action Battery discharged Ignition not switched off when vehicle was parked – Recharge the battery. Battery is not charged by alternator – Check the charging voltage. – Combination instrument shows nothing in the display Fuse 1 blown Speedometer in combination instrument not functioning Speedometer wiring harness is damaged or plug-in connection is oxidized x( p. 111) x Check the quiescent current. x – Change the fuses of individual power consumers. ( p. 115) – Set the clock. ( – Check the wiring harness and plug-in connection. p. 32) 21 BLINK CODE 156 Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Blink code FI of warning lamp (MIL) 09 FI warning lamp (MIL) flashes briefly 9x Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high Blink code FI of warning lamp (MIL) 12 FI warning lamp (MIL) flashes 1x long, 2x short Error level condition Engine coolant temperature sensor - input signal too low Engine coolant temperature sensor - input signal too high Blink code FI of warning lamp (MIL) 13 FI warning lamp (MIL) flashes 1x long, 3x short Error level condition Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high 21 BLINK CODE 157 Blink code FI of warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short Error level condition Ambient air pressure sensor - input signal too low Ambient air pressure sensor - input signal too high Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Error level condition Rollover sensor - input signal too low Rollover sensor - input signal too high Blink code FI of warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short Error level condition Lambda sensor cylinder 1, sensor 1 - circuit fault Blink code FI of warning lamp (MIL) 24 FI warning lamp (MIL) flashes 2x long, 4x short Error level condition System voltage - circuit fault Blink code FI of warning lamp (MIL) 25 FI warning lamp (MIL) flashes 2x long, 5x short Error level condition Side stand switch - circuit fault 21 BLINK CODE 158 Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Motor drive hall sensor - circuit fault Blink code FI of warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code FI of warning lamp (MIL) 41 FI warning lamp (MIL) flashes 4x long, 1x short Error level condition Fuel pump controller - short circuit to ground or open circuit Fuel pump controller - input signal too high Blink code FI of warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code FI of warning lamp (MIL) 54 FI warning lamp (MIL) flashes 5x long, 4x short Error level condition Secondary air valve - short circuit to ground or open circuit 21 BLINK CODE 159 Blink code FI of warning lamp (MIL) 58 FI warning lamp (MIL) flashes 5x long, 8x short Error level condition EPT motor drive relay permission - signal fault Blink code FI of warning lamp (MIL) 60 FI warning lamp (MIL) flashes 6x long Error level condition Motor drive - circuit fault Blink code FI of warning lamp (MIL) 90 FI warning lamp (MIL) flashes 9x long Error level condition Throttle position - circuit fault Blink code FI of warning lamp (MIL) 91 FI warning lamp (MIL) flashes 9x long, 1x short Error level condition CAN bus communication error Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition Motor drive voltage (internal) - circuit fault 22 TECHNICAL DATA 22.1 engine 160 Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.5:1 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,550… 1,650 rpm Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in) Valve play, cold 0.07… 0.13 mm (0.0028… 0.0051 in) Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring Engine lubrication Semi-dry sump lubrication with two rotor pumps Primary transmission 36:79 Clutch APTC™ Antihopping clutch in oil bath/hydraulically operated Gearbox 6-gears, claw-shifted Transmission ratio 1st gear 14:35 2nd gear 16:28 22 TECHNICAL DATA 161 3rd gear 21:28 4th gear 21:23 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter, automatic decompressor 22.2 engine tightening torques Screw, membrane fixation M3 2 Nm (1.5 lbf ft) Loctite® 243™ Hose clip, intake flange M4 2.5 Nm (1.84 lbf ft) – Oil nozzle for conrod bearing lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™ Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, breather cover on valve cover M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, clutch spring M5 6 Nm (4.4 lbf ft) – Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft) – Screw, gear sensor M5 5 Nm (3.7 lbf ft) Loctite® 243™ Screw, oil filter cover M5 6 Nm (4.4 lbf ft) – Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™ 22 TECHNICAL DATA 162 Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw in alternator cover M6 10 Nm (7.4 lbf ft) – Screw, alternator cover (chain shaft through-hole) M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, autodecompression M6 3… 4 Nm (2.2… 3 lbf ft) Loctite® 243™ Screw, axial lock of camshaft M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, clutch cover M6 10 Nm (7.4 lbf ft) – Screw, clutch slave cylinder M6x20 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, clutch slave cylinder M6x35 10 Nm (7.4 lbf ft) – Screw, cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, cylinder head M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, engine case M6 10 Nm (7.4 lbf ft) – Screw, ignition pulse generator M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, oil pump cover M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft) – Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™ Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, stator M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, thermostat housing M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, timing chain guide rail M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, valve cover M6 10 Nm (7.4 lbf ft) – 22 TECHNICAL DATA 163 Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™ Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft) Loctite® 243™ Screw plug, crankshaft clamp M8 20 Nm (14.8 lbf ft) – Stud, exhaust flange M8 10 Nm (7.4 lbf ft) Loctite® 243™ Cylinder head screw M10 Tightening sequence: Tighten diagonally, beginning with the rear screw on the timing chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft) Lubricated with engine oil Oil line for oil pressure sensor M10x1 10 Nm (7.4 lbf ft) – Oil pressure sensor M10x1 10 Nm (7.4 lbf ft) – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Screw plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite® 243™ Screw plug, oil channel, for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain tensioner M10x1 10 Nm (7.4 lbf ft) – Spark plug M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor on cylinder head M12x1.5 12 Nm (8.9 lbf ft) – 22 TECHNICAL DATA Oil drain plug with magnet 164 M12x1.5 20 Nm (14.8 lbf ft) – Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) – Screw plug, oil channel M14x1.5 15 Nm (11.1 lbf ft) Loctite® 243™ Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite® 243™ Rotor nut M18x1.5 100 Nm (73.8 lbf ft) – Nut, engine sprocket M20x1.5 80 Nm (59 lbf ft) Loctite® 243™ Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™ Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite® 243™ Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) – Plug, timing chain tensioner M20x1.5 25 Nm (18.4 lbf ft) – Plug, oil thermostat M24x1.5 15 Nm (11.1 lbf ft) – Screw in alternator cover M24x1.5 8 Nm (5.9 lbf ft) – 22.3 Capacities 22.3.1 Engine oil Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( Alternative engine oil 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 174) Coolant (mixed ready to use) ( p. 175) Engine oil (SAE 10W/50) ( p. 175) p. 174) 22 TECHNICAL DATA 22.3.3 Fuel Total fuel tank capacity, approx. Fuel reserve, approx. 22.4 12 l (3.2 US gal) 165 Super unleaded (ROZ 95/RON 95/PON 91) ( p. 176) 2.5 l (2.6 qt.) chassis Frame Lattice frame made of chrome molybdenum steel tubing, powdercoated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel Front 250 mm (9.84 in) Rear 250 mm (9.84 in) Brake system Front Disc brake with radially screwed four-piston brake caliper, floating brake disc Rear Disc brake with single-piston brake caliper, floating Brake discs - diameter Front 320 mm (12.6 in) Rear 240 mm (9.45 in) Brake discs - wear limit Front 4.0 mm (0.157 in) Rear 4.5 mm (0.177 in) Tire air pressure, solo Front 2.0 bar (29 psi) 22 TECHNICAL DATA 166 Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Secondary drive ratio 16:42 Chain 5/8 x 1/4” X‑ring Steering head angle 63° Wheelbase 1,480±15 mm (58.27±0.59 in) Seat height unloaded 925 mm (36.42 in) Ground clearance unloaded 270 mm (10.63 in) Weight without fuel, approx. 142 kg (313 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.) Maximum permissible overall weight 350 kg (772 lb.) 22.5 Electrical system Battery YTZ10S Battery voltage: 12 V Nominal capacity: 8.6 Ah maintenance-free Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 / socket P43t 12 V 60/55 W 22 TECHNICAL DATA Parking light 167 W5W / socket W2.1x9.5d Instrument lights and indicator lamps LED Turn signal RY10W / socket BAU15s Brake/tail light LED License plate lamp W5W / socket W2.1x9.5d 22.6 12 V 5W 12 V 10 W 12 V 5W Tires Front tires Rear tires 120/70 R 17 M/C 58H TL Continental Conti Attack SM 160/60 R 17 M/C 69H TL Continental Conti Attack SM Additional information is available in the Service section under: http://www.ktm.com 22.7 fork Fork part number 14.18.7L.12 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Rebound damping 22 TECHNICAL DATA 168 Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full load capacity 10 clicks Spring length with preload spacer(s) 462 mm (18.19 in) Spring rate Medium (standard) 5.3 N/mm (30.3 lb/in) Hard 5.6 N/mm (32 lb/in) Air chamber length 100±20 mm (3.94±0.79 in) Fork length 900 mm (35.43 in) Fork oil per fork leg 22.8 644 ml (21.77 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 176) shock absorber Shock absorber part number 15.18.7L.12 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks 22 TECHNICAL DATA 169 Full load capacity 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 20 mm (0.79 in) Spring rate Medium (standard) 80 N/mm (457 lb/in) Hard 85 N/mm (485 lb/in) Spring length 220 mm (8.66 in) Gas pressure 10 bar (145 psi) Static sag 20… 25 mm (0.79… 0.98 in) Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 395 mm (15.55 in) Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( 22.9 chassis tightening torques Screw, chain guard EJOT 2 Nm (1.5 lbf ft) – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, side cover on spoiler EJOT 1 Nm (0.7 lbf ft) – Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) – p. 176) 22 TECHNICAL DATA Fitting, side stand switch 170 M4 2 Nm (1.5 lbf ft) – Screw, fuel hose clamp on fuel tank M4 2 Nm (1.5 lbf ft) – Screw, wheel speed sensor M4 1 Nm (0.7 lbf ft) Loctite® 243™ Spoke nipple, front wheel M4.5 3… 6 Nm (2.2… 4.4 lbf ft) – Spoke nipple, rear wheel M4.5 3… 6 Nm (2.2… 4.4 lbf ft) – Bolt, foot brake lever stub M5 6 Nm (4.4 lbf ft) Loctite® 243™ Remaining nuts, chassis M5 4 Nm (3 lbf ft) – Remaining screws, chassis M5 4 Nm (3 lbf ft) – Screw, brake line holder on swingarm M5 4 Nm (3 lbf ft) – Screw, cable on starter motor M5 3 Nm (2.2 lbf ft) – Screw, electrical holder M5 3 Nm (2.2 lbf ft) – Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) Loctite® 243™ Screw, fuel level sensor M5 3 Nm (2.2 lbf ft) – Screw, fuel pump M5 4 Nm (3 lbf ft) – Screw, fuel tank closure flange M5 2.5 Nm (1.84 lbf ft) – Screw, headlight mask M5 5 Nm (3.7 lbf ft) – Screw, pressure regulator M5 4 Nm (3 lbf ft) – Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) – Remaining screws on fuel tank M6 5 Nm (3.7 lbf ft) – Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Screw connection, foot brake cylinder M6 10 Nm (7.4 lbf ft) – Screw, air filter box top M6 2 Nm (1.5 lbf ft) – Screw, ball joint of push rod on foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, brake fluid reservoir of rear brake M6 5 Nm (3.7 lbf ft) – 22 TECHNICAL DATA 171 Screw, chain guard M6 2 Nm (1.5 lbf ft) Loctite® 243™ Screw, chain guide M6 8 Nm (5.9 lbf ft) – Screw, chain sliding guard M6 8 Nm (5.9 lbf ft) Loctite® 243™ Screw, fan hood M6 4 Nm (3 lbf ft) – Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™ Screw, ignition lock M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, lower radiator bracket M6 8 Nm (5.9 lbf ft) – Screw, magnetic holder on side stand M6 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, radiator guard M6 8 Nm (5.9 lbf ft) – Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™ Screw, seat lock M6 5 Nm (3.7 lbf ft) – Screw, side cover M6 5 Nm (3.7 lbf ft) – Screw, upper radiator bracket M6 10 Nm (7.4 lbf ft) – Screw, voltage regulator M6 8 Nm (5.9 lbf ft) – Nut, manifold on cylinder head M8 20 Nm (14.8 lbf ft) Copper paste Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 2701 Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) – Remaining screws, chassis M8 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) – Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) – Screw, connection lever on frame M8 30 Nm (22.1 lbf ft) Loctite® 243™ Screw, exhaust clamp on main silencer M8 12 Nm (8.9 lbf ft) Copper paste Screw, foot brake lever M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, fork stub M8 15 Nm (11.1 lbf ft) – 22 TECHNICAL DATA 172 Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) – Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) – Screw, fuel tank, bottom M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, fuel tank, top M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) – Screw, handrail M8 20 Nm (14.8 lbf ft) – Screw, heel protector M8x12 5 Nm (3.7 lbf ft) Loctite® 243™ Screw, license plate holder, top M8 20 Nm (14.8 lbf ft) – Screw, main silencer holder M8 25 Nm (18.4 lbf ft) – Screw, main silencer holder on fuel tank M8 25 Nm (18.4 lbf ft) – Screw, rear footrest bracket M8x16 25 Nm (18.4 lbf ft) – Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, spring holder on side stand bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™ Screw, steering stem M8 20 Nm (14.8 lbf ft) – Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™ Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) – Remaining screws, chassis M10 45 Nm (33.2 lbf ft) – Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™ Screw, engine bearer on frame M10 45 Nm (33.2 lbf ft) – Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™ Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite® 243™ Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™ 22 TECHNICAL DATA 173 Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™ Screw, swingarm pivot M12 80 Nm (59 lbf ft) – Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Copper paste Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) – Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft) – Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite® 243™ Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – 23 SUBSTANCES 174 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Guideline – Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends Motorex® products. Mixture ratio Antifreeze protection: −25… −45 °C (−13… −49 °F) 50 % corrosion inhibitor/antifreeze 50 % distilled water Coolant (mixed ready to use) Antifreeze Supplier Motorex® – COOLANT G48 −40 °C (−40 °F) 23 SUBSTANCES 175 Engine oil (SAE 10W/60) (00062010035) According to – JASO T903 MA ( – SAE ( – KTM LC4 2007+ p. 181) p. 181) (SAE 10W/60) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Cross Power 4T Engine oil (SAE 10W/50) According to – JASO T903 MA ( – SAE ( p. 181) p. 181) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Fully synthetic engine oil Supplier Motorex® – Power Synt 4T 23 SUBSTANCES 176 Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 181) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex® – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 181) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) 23 SUBSTANCES Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100). 177 24 AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex® products. Supplier Motorex® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex® products. Supplier Motorex® – Protect & Shine Fuel additive Guideline – KTM recommends Motorex® products. Supplier Motorex® – Fuel Stabilizer 178 24 AUXILIARY SUBSTANCES High-luster polish for paint Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Polish Long-life grease Guideline – KTM recommends Motorex® products. Supplier Motorex® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900 Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex® products. Supplier Motorex® – Clean & Polish 179 24 AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex® products. Supplier Motorex® – Joker 440 Synthetic 180 25 STANDARDS 181 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements. SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality. INDEX 182 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Air filter installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Battery fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Blink code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156-159 Brake discs checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Brake fluid front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Brake fluid level front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 87 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Brake linings front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 C Capacity coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144, 164 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 165 Chain checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 dirt, checking for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Chain guide checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Chain tension adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Changing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Clutch checking/correcting fluid level . . . . . . . . . . . . . . . . . . . . 85 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 84 Combination instrument clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . 35 INDEX 183 display . . . . . . . . . . . . . . . . function buttons . . . . . . . . . . Indicator lamps . . . . . . . . . . kilometers or miles, setting . . ODO display . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . speed display . . . . . . . . . . . . tachometer . . . . . . . . . . . . . time . . . . . . . . . . . . . . . . . . TRIP 1 display, setting/resetting TRIP 2 display, setting/resetting TRIP F display . . . . . . . . . . . . Coolant draining . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . 28 . 29 . 31 . 33 . 27 . 31 . 28 . 32 . 33 . 34 . 35 Engine oil adding . changing draining refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 139 139 144 Engine oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Engine sprocket checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Coolant level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126, 128 Filler cap closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Filling up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 91 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 E Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Engine characteristic adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . compression damping, adjusting . . . . . . . . . . . . . . . . . . dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork part number 60 . 60 . 71 . 70 . 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INDEX 184 Fork protector installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Front wheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Fuse of individual power consumer, changing . . . . . . . . . . . . . 115 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 86 Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Headlight light range, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 125 K L M Main fuse changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Motorcycle cleaning . . . . . . . . . . . . . . . . . raising with lift stand . . . . . . . . raising with the front wheel stand raising with the rear wheel stand . removing from the lift stand . . . . taking off of the front wheel stand taking off of the rear wheel stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 . 67 . 69 . 68 . 67 . 70 . 69 Headlight bulb, changing . . . . . . . . . . . . . . . . . . . . . . . . . . 120 O Headlight mask with headlight installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Oil filter changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Headlight setting, checking . . . . . . . . . . . . . . . . . . . . . . . . . 124 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 I Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Oil screens cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139, 142 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INDEX P Parking 185 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parking light bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Play in throttle cable adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Seat release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59 Preparing for use checks and vehicle care when preparing for use . . . . . . . . 45 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . 136 basic position, checking . . . . . . . . . . . . . . . . . . . . . . . 136 Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Putting into operation advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 R Rear hub rubber dampers checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Rear sprocket checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Rear wheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . compression damping, general . . . . . . . . . . . . . . . . . . . compression damping, high-speed, adjusting . . . . . . . . . compression damping, low-speed, adjusting . . . . . . . . . . rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . . 60 . 62 . 63 . 62 . 64 Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . . 22 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Spoke tension checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Starting . . . Steering lock Stopping . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . 27 . 52 150 INDEX 186 rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 T Technical data capacities . . . . . . . . . . . chassis . . . . . . . . . . . . . chassis tightening torques electrical system . . . . . . engine . . . . . . . . . . . . . engine tightening torques fork . . . . . . . . . . . . . . . shock absorber . . . . . . . . tires . . . . . . . . . . . . . . . W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 165 169 166 160 161 167 168 167 Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Tire air pressure checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Tire condition checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Transport . . . . . . . Troubleshooting . . . Tubeless tire system Turn signal switch . . Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 153-155 . . . . 106 . . . . . 25 . . . . . 20 U Use definition ...................................8 V View of vehicle front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Winter operation checks and maintenance steps . . . . . . . . . . . . . . . . . . . 149 Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 *3211954en* 3211954en 11/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM